Current status and development trend of welding power source testing equipment (2)
b) The second generation of testing equipment is represented by the digital TDC series power supply test bench researched and produced by Chengdu Electric Inspection Institute and Chengdu Sanfang Electric Co., Ltd., replacing the pointer type table with digital instrument, and the Hall current sensor replaces the transformer and the shunt. In terms of function and test accuracy, it is consistent with the first generation equipment, but the volume is greatly reduced, the use and maintenance are greatly improved, the reading is intuitive, and the operation is convenient. It is widely used by most welding power production enterprises in the country. But it still has the disadvantages of the first generation of equipment.
c) The development of modern manufacturing technology and welding production, the requirements for testing equipment, real-time and test accuracy of welding equipment are constantly improving, making the limitations of traditional testing instruments in structure and function increasingly prominent, difficult to adapt and meet Modern inspection work with high efficiency and large information needs. The third generation of testing equipment is based on the prototype of the “Intelligent AC/DC Power Supply Test System†of the National Science and Technology Ministry's special fund project, which was developed by Chengdu Sanfang Electric Co., Ltd., and the new generation of PTE series information was launched after the second development and design. The detection system is a typical representative. It uses virtual instrument technology as the implementation platform, which has the advantages of large amount of information, fast detection speed, excellent man-machine interface, high test accuracy and strong flexibility. It also realizes harmonic current analysis, power factor and efficiency of arc welding power supply. Real-time measurement of important parameters.
The detection system has the following features in structure:
(1) Using virtual instrument technology as an implementation platform. The host selects NI PXI-8174 embedded controller, the data acquisition uses PXI-6071E multi-function card of PXI interface, and the load control adopts PLC as the main control unit. The host-side program is event-driven.
(2) Using distributed (DCS) control method, a large system with more state variables is decomposed into several independent modules. The configuration and expansion of the system are very convenient, centralized management, decentralized control, and effectively enhance the automatic test. System flexibility.
(3) In the software environment, using the common Windows 2000 operating system, it is beneficial to make full use of the existing software resources, the programming environment is LabVIEW, and is divided into front panel and source code. The front panel forms the main interface of the program with WYSIWYG technology.
The detection system integrates a variety of new computer and information technology advantages, can quickly and easily complete the electrical test of the welding power supply, and can visually see the details of each measured waveform, which helps to understand and understand. The physical meaning of each test quantity has the following features in function:
(1) Intelligent programmatic load adjustment. According to the type of welder input by the user, when the load needs to be adjusted, the main system will automatically send a command to the PLC, and the PLC determines the state of its output contact according to the command, thereby controlling the on/off of the non-inductive load resistance control contactor to achieve the regulated load. the goal of. The entire process has no need for manual intervention, that is, to automatically find a working point.
(2) The grid voltage is automatically stabilized. In order to ensure the consistency of the test conditions, the input voltage of the welding power supply should be stable within a certain error range, and the grid voltage is often affected by the load and other factors around it, and there will be large fluctuations. The detection system uses the microcontroller voltage regulation technology to automatically monitor the power grid.
(3) Detection and analysis of harmonic currents. Harmonics are an important feature of power electronics and a major hazard to pollute the power grid. From the perspective of harmonic suppression, it is important that the magnitude of the harmonics and the real-time measurement are made. The full function of the harmonic current detection module based on the instantaneous reactive power theory in the system is realized by software, and all the intermediate quantities of the detection process can be observed and recorded.
(4) Power factor is an important indicator to measure the quality of equipment power. It reflects the utilization of electric energy by equipment and is an important basis for evaluating and developing high-efficiency new welding power sources. The electronically controlled welding power source often causes severe distortion of the input current. The traditional method of describing the power factor by the power factor angle is not applicable. The system uses the waveform calculation method to design the object as a whole and is designed for three-phase. The power factor measurement module of the power supply avoids the effects of non-sinusoidal signals and three-phase unbalance, and solves the problem that the phase voltage cannot be accurately obtained in the project. A new detection method is provided for accurately evaluating the performance of the welding power source.
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